25. Maintenance Operation


[SOUND] Welcome back to our lesson on maintenance operations. Upon completion of this lesson, learners should be able to recognize the role and importance of maintenance service operations in helping to ensure equipment availability and reliability. Understand the various functions performed by maintenance and discuss the role of maintenance spares. The maintenance function exists to provide services to operations, to ensure that plant and equipment is safe, reliable and available for manufacturing purposes. The primary goal of the maintenance function is to plan and conduct activities and work tasks to mitigate equipment failure. Ideally, maintenance should be performed to prevent equipment failures by replacing components and parts before they break, performing planned overhauls, lubrications and adjustments.
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When equipment does break or fail, maintenance needs to have the necessary trained personnel and access to spare and replacement parts to quickly and effectively make the machine operational. While maintenance keeps operations in the supply chain running, it is also interesting to note that in many ways, there’s a whole integrated supply chain involved with maintenance itself. Parts, people, and other resources need to be planned, sourced, manufactured, transported and stored to support maintenance operations.
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The key functions of maintenance include breakdown repairs, repairs carried out on equipment or machinery that has broken down during the course of normal operation.
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Overhaul, repairing and maintaining a piece of equipment or machinery to restore it to working condition. Rebuild, building a piece of equipment or machinery to working condition after it has reached the end of its normal working life or after it has been damaged. Service, during the normal course of work, the maintenance personnel perform routine operations, carried out on a regular basis, to keep machinery and equipment functioning effectively, including minor adjustments and periodic lubrication.
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Modification, making a small adjustment, change or addition to a piece of equipment or machinery to improve the operational output.
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Inspection, performing a physical examination or review. Inspection involves taking measurements and performing tests with gauges to determine proper functionality to a standard.
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Replacements, changing out a piece of equipment or machinery or a component of this equipment or machinery when it has reached the end of its useful life.
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In order to support maintenance operations, spare parts and some assemblies are required to ensure that the plant and equipment is kept in reliable and safe condition. When you think about the dozens of individual parts that may comprise a single machine, say an air conditioner, then extrapolate that to the dozens of pieces of equipment that are found in a manufacturing facility, perhaps you can get an appreciation for the level of investment involved with managing inventories for maintenance.
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Process industry companies with a need to minimize down time
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due to out of commission critical equipment and utilities that must work to restore operations after a weather emergency, they hold millions of dollars of spare parts inventory.
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In addition to spare parts, there are a number of other materials that may be needed to conduct the maintenance operations. Typically these are relatively low value materials called usage materials, which are used on a regular basis. Examples are fasteners, cleaning materials, lubrication materials and other consumables such as paper towels.
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Scheduled spares are used whenever a planned maintenance task is performed. They could include internal machine parts or roller bearings on conveyors. Air filters for HVAC systems may also be considered as scheduled spares. Project materials, used for a planned project and could include internal parts to rebuild a machine to a significant extent.
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Breakdown spares, used when breakdowns occur to replace broken or nonfunctioning spares.
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Insurance spares, used to protect against natural disasters. They could consist of an entire machine or a set of machines to enable manufacturing to continue to operate.
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We have a question for you to ask now. Think about a time when there was equipment failure at your home, place of work, or elsewhere. What was the cause of the failure? What was involved in the repair operation in terms of staffing, spare parts and the other materials to support the repair operation? How about tools needed to support the repair operation?
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In this lesson, we’ve discussed the role and importance of maintenance service operations in helping to ensure equipment availability and reliability. We’ve discussed the functions performed by maintenance and discussed the role of maintenance spares. Thank you and we’ll see you on the next lesson. [SOUND]

Jim Rohn Sứ mệnh khởi nghiệp